Lower Manifold Assembly
Removal Procedure
1. Relieve fuel system pressure. Refer to the Fuel Pressure Relief Procedure.
2. Remove the negative battery cable.
3. Remove the upper manifold assembly.
4. Remove the quick-connect fittings at engine compartment fuel feed and return pipes.
5. Use compressed air in order to blow out dirt from all quick-connect fittings before removing.
6. Grasp both ends of one fuel pipe connection and twist 1/4 turn in each direction to loosen any dirt in quick-connect fitting. Repeat for other fitting.
7. Choose correct tool from J 37088-A tool set for size of fitting.
8. Insert tool into female connector, then push inward to release male connector.
9. Repeat for other fitting.
10. Remove the plug fuel feed and return pipes as required.
11. Remove the bolts retaining power steering pump brace, and brace.
12. Remove the engine fuel inlet pipe retainer nuts and retainers.
13. Remove the fuel inlet pipe and seal.
14. Remove the transmission fill tube attaching nut.
15. Remove the lower manifold attaching nuts (3).
16. Remove the lower manifold (2). Discard gasket (1)
Notice: In order to prevent damage to the sealing surfaces, carefully use sharp tools in cleaning the old gasket from the aluminum surfaces.
17. Whenever it is necessary to remove rust or burrs from the male tube end of the fuel feed/return pipes quick-connect fittings, use emery cloth in a circular motion with the tube end to prevent damage to O-ring sealing surface.
18. Gasket mating surfaces.
19. Using a clean shop towel, wipe off male tube end of the fuel feed/return pipes quick-connect fittings. Replace pipes if damaged.
20. Inspect the lower manifold for items that are to be transferred to the new manifold.
21. Disassemble the lower manifold and other remaining parts to be transferred following component repair procedures.
22. Assemble the replacement lower manifold with transferred parts following component repair procedures.
Installation Procedure
1. Install the new lower manifold gasket (1).
2. Position lower manifold (2) on studs.
3. Install the fuel inlet pipe retaining nut. Tighten the fuel inlet pipe retaining nut to 30 Nm (22 lb. ft.).
4. Install the fuel pipe support nut. Tighten the fuel pipe support nut to 10 Nm (89 lb. in.).
5. Install the lower manifold attaching nuts (3). Tighten the lower manifold attaching nuts 30.0 Nm (22 lb. ft.), using tightening sequence.
6. Install the transmission fill tube attaching nut.
7. Install the new fuel inlet pipe O-ring seal.
8. Install the fuel inlet pipe nut (Finger tighten only).
9. Support nut on bottom of lower manifold (Finger tighten only).
Caution: In order to reduce the risk of fire and personal injury, before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.
10. Install the power steering pump brace with attaching bolts.
11. Unplug fuel feed and return pipes.
Important:
^ Apply a few drops of clean engine oil to the male tube ends of the engine fuel feed and return pipes.
^ Push connectors together to cause the retaining tabs/fingers to snap into place.
^ Once installed, pull on both ends of each connection to make sure they are secure.
^ Repeat for other fitting.
12. Install the fuel feed and return line quick-connect fittings
13. Install the upper manifold assembly.
14. Tighten fuel filler cap.
15. Install the negative battery cable.
16. Inspect for leaks.
16.1. Turn the ignition switch ON for 2 seconds.
16.2. Turn the ignition switch OFF for 10 seconds.
16.3. Turn the ignition switch ON.
16.4. Check for fuel leaks.